DIY...Fluid container external attachment to pannier step-by-step

klm4755 · 08-26-2012, 06:22 PM

Enclosed is a step by step outline to create a fail-safe strap and bracket system to attach fluid containers to the rear of a happy trails panniers.

The bottles to attach. They carry 27 oz of liquid, and are fully stainless steel. From Klean Kanteen

Even the cap is stainless steel, the fluid is not in contact with the seal

want to mount here on the pannier

First I'll make the base, the container is 2.75 inch in diameter, circle template is used for scribing the base size

mark and cut, aluminum base, .050 inch gage

sand base to final size

deburr edge of base with this tool

quick size check

need 6x strap attach connectors

drill

cut to size, and deburr

trim base bracket to pannier

sand 220 grit and primer all parts with 2x coats

counter sink to accept flush fastener

need nylon webbing

trim to rough size to attach bottle

paint straps and plastic buckles

All parts painted with Krylon ultra flat paint

base bracket fastened

ACU camo base bracket

Attach nylon webbing on pannier with Al strap connectors, Key is to form large melted end on webbing

Attach mid-way up bottle

quick fit check, can cinch up pretty tight

install base plate, fluid container will rest on base bracket

Add top strap to thread thru bottle cap, sew with plastic buckle with nylon thread

finished product

view without bottle

Another view with buckles engaged

Bottle attached, note fail-safe design, One strap can fail, although not likely, but the bottle remains attached to pannier

Bike rear view

Enjoy...
Observations:
1. Easy, custom install
2. Costs of straps, buckles and al about $6.00
3. The only fluid planning to carry is water
4. No issues after ~1,000 miles
5. Not sure the value of locking bottles to bike. Don't think anyone would mess with them.
Keithm

klm4755 · 08-28-2012, 07:33 PM

Here is a close-up of strap melted end, I used a soldering iron to form the Blunt end to restrain the webbing in the aluminum tie down

off-set side view of strap attach

Jnich77 · 08-28-2012, 07:45 PM

I absolutely love it... wait, when the army changes to "Milti-cam" are you going to redo the bike?

Unstable Rider · 08-28-2012, 08:22 PM

I think I know that bike.....

I am a huge fan, not a hater.

You have mad ambitions (mad skills).

+1 brother.

You going to port some fuel in em?

I have some Agri-tool tubes and I have carried a bit of gas in one of those metal drink bottles like you got there, at least the largest one that fit the big Agri-tube. Never had it leak or drip. Carry a bit of oil in another on trips. Yes, I drive a KLR....

Going to rig some on an old Honda ATC I have for deer hunting...

klm4755 · 08-29-2012, 11:35 AM

Quote:

Originally Posted by Jnich77

I absolutely love it... wait, when the army changes to "Milti-cam" are you going to redo the bike?

Not likely, although the ACU digital desert camo part of the bike can be removed, it would be a couple day work to re-bond new camo material.
Keithm

klm4755 · 09-22-2012, 05:45 PM

Quote:

Originally Posted by Unstable Rider

I think I know that bike.....

I am a huge fan, not a hater.

You have mad ambitions (mad skills).

+1 brother.

You going to port some fuel in em?

I have some Agri-tool tubes and I have carried a bit of gas in one of those metal drink bottles like you got there, at least the largest one that fit the big Agri-tube. Never had it leak or drip. Carry a bit of oil in another on trips. Yes, I drive a KLR....

Going to rig some on an old Honda ATC I have for deer hunting...

Right now the containers are just full of water, maybe fuel in the future
Keithm

newcastleadam · 09-26-2012, 08:32 AM

Been awhile since I've seen you post up, glad you're back. Always enjoy your threads

DirtyOldMan · 09-26-2012, 08:32 PM

Quote:

Originally Posted by newcastleadam

Been awhile since I've seen you post up, glad you're back. Always enjoy your threads

Yeah, I always read em, even if I have no interest in the finished product, the process and description are always top notch.

TV show?

klm4755 · 09-29-2012, 06:55 PM

Quote:

Originally Posted by DirtyOldMan

Yeah, I always read em, even if I have no interest in the finished product, the process and description are always top notch.

TV show?

Thanks...Always busy here tinkering...I added another Stainless Bottle to the left Pannier. This brings the total exterior fluid level to 81 oz.

Added bottle

Rear bike view

centered rear View.
Enjoy!
Keithm

hardybaker · 10-01-2012, 04:20 AM

Where did you buy those Allen headed fasteners?

staikosn1 · 10-03-2012, 10:48 AM

Excellent DIY

Too much camo

.

Grats mate.

Dubl-A · 10-03-2012, 03:22 PM

Now that is cool Bro! Nice job

08-26-2012, 06:22 PM	#1
klm4755 ^OP Studly Adventurer Joined: Jun 2006 Oddometer: 526	DIY...Fluid container external attachment to pannier step-by-step Enclosed is a step by step outline to create a fail-safe strap and bracket system to attach fluid containers to the rear of a happy trails panniers. The bottles to attach. They carry 27 oz of liquid, and are fully stainless steel. From Klean Kanteen Even the cap is stainless steel, the fluid is not in contact with the seal want to mount here on the pannier First I'll make the base, the container is 2.75 inch in diameter, circle template is used for scribing the base size mark and cut, aluminum base, .050 inch gage sand base to final size deburr edge of base with this tool quick size check need 6x strap attach connectors drill cut to size, and deburr trim base bracket to pannier sand 220 grit and primer all parts with 2x coats counter sink to accept flush fastener need nylon webbing trim to rough size to attach bottle paint straps and plastic buckles All parts painted with Krylon ultra flat paint base bracket fastened ACU camo base bracket Attach nylon webbing on pannier with Al strap connectors, Key is to form large melted end on webbing Attach mid-way up bottle quick fit check, can cinch up pretty tight install base plate, fluid container will rest on base bracket Add top strap to thread thru bottle cap, sew with plastic buckle with nylon thread finished product view without bottle Another view with buckles engaged Bottle attached, note fail-safe design, One strap can fail, although not likely, but the bottle remains attached to pannier Bike rear view Enjoy... Observations: 1. Easy, custom install 2. Costs of straps, buckles and al about $6.00 3. The only fluid planning to carry is water 4. No issues after ~1,000 miles 5. Not sure the value of locking bottles to bike. Don't think anyone would mess with them. Keithm

08-28-2012, 08:22 PM	#4
Unstable Rider World Wide Inmate Joined: Jul 2010 Location: 10,000 Lakes Oddometer: 2,116	I think I know that bike..... I am a huge fan, not a hater. You have mad ambitions (mad skills). +1 brother. You going to port some fuel in em? I have some Agri-tool tubes and I have carried a bit of gas in one of those metal drink bottles like you got there, at least the largest one that fit the big Agri-tube. Never had it leak or drip. Carry a bit of oil in another on trips. Yes, I drive a KLR.... Going to rig some on an old Honda ATC I have for deer hunting... __________________ ´¯`·.¸¸.·´¯`·.¸ ><((((((º> `·.¸¸.·´¯`·.¸¸.·´¯`·.¸ ><((((º> ´¯`·.¸¸.·´¯`·.¸¸.·´¯`·.¸ ><((((((º> Everything happens for a reason. "Still seeking the reason"

09-26-2012, 08:32 AM	#7
newcastleadam Artful Tagger Joined: Oct 2007 Location: Gainesville, Fl Oddometer: 3,422	Been awhile since I've seen you post up, glad you're back. Always enjoy your threads __________________ Adam 86 KLR250 01 KLR685 06 K1200LT As ever, buyer and seller of all things KLR KLR Doohickey Wrench available! The North Florida Tag-O-Rama wants YOU!

10-01-2012, 04:20 AM	#10
hardybaker Gnarly Adventurer Joined: Apr 2003 Location: Marquez, Texas Oddometer: 331	????? Where did you buy those Allen headed fasteners?

10-03-2012, 10:48 AM	#11
staikosn1 Adventurer Joined: Jun 2011 Location: Greece Oddometer: 77	Excellent DIY Too much camo. Grats mate.

08-28-2012, 07:33 PM	#2
klm4755 ^OP Studly Adventurer Joined: Jun 2006 Oddometer: 526	Here is a close-up of strap melted end, I used a soldering iron to form the Blunt end to restrain the webbing in the aluminum tie down off-set side view of strap attach

08-28-2012, 07:45 PM	#3
Jnich77 Gnarly Adventurer Joined: Aug 2012 Location: Orlando Fl Oddometer: 303	I absolutely love it... wait, when the army changes to "Milti-cam" are you going to redo the bike?

10-03-2012, 03:22 PM	#12
Dubl-A MADE IN BURQUE Joined: Mar 2009 Location: 505 Oddometer: 566	Now that is cool Bro! Nice job

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